MIM process is based on 5 main stages:

1) Preparation of the Feedstock: Metal powders (with particle size of a few microns) are mixed hot with organic binders (typically wax, thermoplastic resins and other materials) until a homogenous mixture is obtained. After cooling, the mixture is granulated, to allow it to be fed into an injection molding machine. If necessary, it can then be stored for a practically unlimited amount of time.

2) Injection Molding - Injection of the feedstock is done using an injection molding machine, similar to those used in the plastic industry. The feedstock is melted in the cylinder at a temperature of approximately 165°C and then injected into the mold. The injected metal parts (called "green parts") are formed into the desired geometry, with allowance for shrinkage. They then undergo visual inspection by means of a stereoscope and are weighed and checked for density. Rejected parts are granulated and recycled.

3) Debinding - After producing the green parts it is necessary to remove the organic binders before sintering. Here technologies vary. Metaor uses a process which consists of two stages: 1 - removal of the binder with an organic solvent, and 2 - thermal burnoff of the plasticizers.

4) Sintering - The final stage of the metal sintering process is sintering which is performed in a high temperature - controlled atmosphere furnace or in a vacuum furnace. In this stage the residual binder is removed and shrinkage occurs. At the end of the sintering process, the parts have shrunk by 15-18% and reach the precise desired dimensions. Shrinkage is unique for each metal alloy and is similar along the three axes.

5) Secondary operations are required for some parts. These may include:

- deburring - removal of flashes that occur during injection - done after debindingand before sintering.

- calibration - especially for parts with thin and long walls that could be slightly warped during sintering.

- thermal treatments

- surface treatments

MIM technology offers significant advantages:

- High precision.

- Metal parts can be machined, heat-treated, coated or plated.

- Ability to produce complex and intricate parts in large quantities.

- High level of surface finish.

- Tight tolerances of up to +/- 0.3% of the desired measurements.

- High density of 97% and more of the theoretical density of the material.

- Lower cost per unit.

It is important to note that the economical advantage of MIM over other technologies is especially significant for orders of large quantities (5000+) of complex small metal parts which weigh less than 5 gram to 50 grams. (The savings can be up to 50%). With the MIM technology, very near net shape parts are obtained and therefore is most advantageous for parts normally produced entirely by machining or where machining is necessary as a secondary operation.

Applications

Some of the most common applications are:

1. Injection molded components for the electronic and electro-optic industries,

2. Computer peripherals such as disk drive parts, printer heads,

3. Copier machines.

4. Parts for hand tools.

5. Firearm parts.

6. Sporting goods.

7. Magnetic applications.

8. Medical instruments.

9. Household appliances.

10. Dental, orthodontic brackets and components.

11. Automotive assemblies.

12. Aerospace industry.

13. Components for servo-mechanical and remote-control instruments.

Size

Even though it is possible to produce parts larger than 100 mm with a weight of 100 grams upwards, our experience shows that a cost advantage is reached mainly for smaller parts. Tolerances As in other production technologies, it is always advisable to mention tolerances which are not tighter than needed in order to lower the production cost. In the MIM technology it is usually possible to get to precision in the tolerance of up to 0.3% of the dimension, but not less than 0.02 mm. Higher precision requires grinding as a secondary operation.